US8261593B1 - Leak detector for heat exchanger - Google Patents

Leak detector for heat exchanger Download PDF

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Publication number
US8261593B1
US8261593B1 US12/572,740 US57274009A US8261593B1 US 8261593 B1 US8261593 B1 US 8261593B1 US 57274009 A US57274009 A US 57274009A US 8261593 B1 US8261593 B1 US 8261593B1
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heat exchanger
container
port
leak
water
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US12/572,740
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Leon Sanders
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M3/00—Investigating fluid-tightness of structures
    • G01M3/02—Investigating fluid-tightness of structures by using fluid or vacuum
    • G01M3/26—Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors
    • G01M3/32—Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors for containers, e.g. radiators
    • G01M3/3236—Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors for containers, e.g. radiators by monitoring the interior space of the containers
    • G01M3/3245—Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors for containers, e.g. radiators by monitoring the interior space of the containers using a level monitoring device
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M3/00—Investigating fluid-tightness of structures
    • G01M3/02—Investigating fluid-tightness of structures by using fluid or vacuum
    • G01M3/04—Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point
    • G01M3/06—Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point by observing bubbles in a liquid pool
    • G01M3/10—Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point by observing bubbles in a liquid pool for containers, e.g. radiators
    • G01M3/106—Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point by observing bubbles in a liquid pool for containers, e.g. radiators for radiators

Definitions

  • This invention relates to detection of leaks in heat exchangers, and more specifically to visible detection of a leak from one heat exchanger side to the other heat exchanger side using gas pressure build-up to create bubbles in a liquid outside the heat exchanger.
  • Heat exchangers comprise a first side, sometimes referred to as a product side, and a second side, sometimes referred to as a media side, in close contact with the first side.
  • Plate heat exchangers that comprise a number of plates closely packed in series with fluids flowing through them while maintaining the two sides separate. Plate heat exchangers are commonly used in food processing where it is imperative that the fluids from the two sides remain separate, that is, that there are no leaks between the two heat exchanger sides that could cause cross contamination. Cross contamination occurs when a crack or pinhole develops, allowing fluids on one side to pass from one side into the other side and mix with fluids on that side usually assisted by a pressure difference that exists between the two sides. Because contamination can have serious consequences, it is routine to check the plates for any defect that may result in a leak.
  • This object is achieved in a heat exchanger leak detector that employs a bubble detector to detect gas pressure build up in a heat exchanger's second side from leakage of pressurized gas introduced in a heat exchanger's first side.
  • the detector employs a U-shaped container for receiving a liquid, such as water, a modified plug adapted to connect to an exchanger port, and a tube running between them providing fluid communication between the modified plug and the container.
  • a liquid such as water
  • a modified plug adapted to connect to an exchanger port
  • a tube running between them providing fluid communication between the modified plug and the container.
  • the top of the container is typically closed. Therefore gas released from the bubbles causes a pressure build-up in the container above the water. When pressure builds up above the water, a water level difference between the two container legs follows, creating a further visible indicator of the leak
  • the device is adapted for use outside the exchanger system as a simple and temporary leak detector.
  • it may be used with any heat exchanger design by simply connecting the detector to a port on one side of the heat exchanger, supplying air pressure to a port on the other side and sealing all remaining ports. It is then easily removed for normal operation of the heat exchanger. Because air can be used to pressurize the first side of the heat exchanger and water can be used in the container, the detector is inexpensive to use and quick to install.
  • FIG. 1 is a perspective view of the heat exchanger leak detector of the present invention.
  • FIG. 2 is a side view of the heat exchanger leak detector of FIG. 1 , shown connected to a heat exchanger port and with bubbles visible in water in the first leg of the U-shaped container.
  • FIG. 3 is a perspective view of the heat exchanger leak detector of FIG. 1 shown connected to a port on one side of the heat exchanger and pressurized gas supplied to a port on the other side of the heat exchanger with other heat exchanger ports capped.
  • the gas leak detector 10 of the present invention for use with a heat exchanger 100 comprises a modified port plug 12 adapted to fit in a first heat exchanger port 102 that provides access to a heat exchanger's first side (not shown), with a hole 14 through the modified plug 12 .
  • a second port plug 15 connects to second heat exchanger port 104 to which a supply of pressurized air 106 is connected.
  • the second heat exchanger port 104 provides access to a heat exchanger second side (not shown).
  • a tube 16 extends from the hole 14 into a container 17 that can be filled with a liquid 18 , typically water.
  • the container 17 is a generally U-shaped with first and second legs 20 , 22 extending upward from a bottom 24 .
  • the first leg 20 connects to the modified plug 12 with an air tight seal.
  • the tube 16 extends from the modified plug 12 into the first leg 20 of the U-shaped container 17 to a tube end position 26 below a position 28 to which water, or other equivalent liquid, is filled during use.
  • the second leg 22 is typically open to the atmosphere to allow the water level to adjust without pressure in the second leg 22 .
  • It also may be closed to create a difference in water level in the two legs 20 , 22 when the first leg 20 is pressurized by air from the heat exchanger's second side in the instance that pressurized air passes through a leak between the heat exchanger's first and second sides, in which case a fill port is provided in the container into which the liquid can be poured into and out of the container 16 .
  • the detector is left for a longer period of time to allow gas to be released from bubbles over that longer time which accumulates and pressurizes the first leg 20 above the water level, which causes a difference in water level between the container's first and second legs 20 , 22 , which is a more sensitive indicator of a leak.

Abstract

A heat exchanger leak detector employs a bubble detector to detect gas pressure build up in a heat exchanger second side from leakage of pressurized gas introduced in a heat exchanger first side.

Description

BACKGROUND
1. Field of the Invention
This invention relates to detection of leaks in heat exchangers, and more specifically to visible detection of a leak from one heat exchanger side to the other heat exchanger side using gas pressure build-up to create bubbles in a liquid outside the heat exchanger.
2. Prior Art
Heat exchangers comprise a first side, sometimes referred to as a product side, and a second side, sometimes referred to as a media side, in close contact with the first side. Plate heat exchangers that comprise a number of plates closely packed in series with fluids flowing through them while maintaining the two sides separate. Plate heat exchangers are commonly used in food processing where it is imperative that the fluids from the two sides remain separate, that is, that there are no leaks between the two heat exchanger sides that could cause cross contamination. Cross contamination occurs when a crack or pinhole develops, allowing fluids on one side to pass from one side into the other side and mix with fluids on that side usually assisted by a pressure difference that exists between the two sides. Because contamination can have serious consequences, it is routine to check the plates for any defect that may result in a leak.
Checking for defects usually involves removing a plate and testing it apart from the heat exchanger. Disassembly of the heat exchanger is time consuming and interrupts its use. The need remains for a device and method that can perform a quick and easy test on a heat exchanger in place without removal and disassembly of the heat exchanger to minimize interruption of use of the heat exchanger.
SUMMARY OF THE INVENTION
This object is achieved in a heat exchanger leak detector that employs a bubble detector to detect gas pressure build up in a heat exchanger's second side from leakage of pressurized gas introduced in a heat exchanger's first side.
The detector employs a U-shaped container for receiving a liquid, such as water, a modified plug adapted to connect to an exchanger port, and a tube running between them providing fluid communication between the modified plug and the container.
When there is a leak in the heat exchanger, air pressure from the heat exchanger first side passes through the leak into the heat exchanger's second side, which pressure passes through the tube into water in the U-shaped container. When gas pressure builds up over the head in the tube portion that is below water level is discharged from the tube's second end and into the water forming bubbles of the gas to rise in the water from the tube's second end, providing a visual indicator of gas build up.
The top of the container is typically closed. Therefore gas released from the bubbles causes a pressure build-up in the container above the water. When pressure builds up above the water, a water level difference between the two container legs follows, creating a further visible indicator of the leak
The device is adapted for use outside the exchanger system as a simple and temporary leak detector. Thus, it may be used with any heat exchanger design by simply connecting the detector to a port on one side of the heat exchanger, supplying air pressure to a port on the other side and sealing all remaining ports. It is then easily removed for normal operation of the heat exchanger. Because air can be used to pressurize the first side of the heat exchanger and water can be used in the container, the detector is inexpensive to use and quick to install.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the heat exchanger leak detector of the present invention.
FIG. 2 is a side view of the heat exchanger leak detector of FIG. 1, shown connected to a heat exchanger port and with bubbles visible in water in the first leg of the U-shaped container.
FIG. 3 is a perspective view of the heat exchanger leak detector of FIG. 1 shown connected to a port on one side of the heat exchanger and pressurized gas supplied to a port on the other side of the heat exchanger with other heat exchanger ports capped.
 DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The gas leak detector 10 of the present invention for use with a heat exchanger 100 comprises a modified port plug 12 adapted to fit in a first heat exchanger port 102 that provides access to a heat exchanger's first side (not shown), with a hole 14 through the modified plug 12. A second port plug 15 connects to second heat exchanger port 104 to which a supply of pressurized air 106 is connected. The second heat exchanger port 104 provides access to a heat exchanger second side (not shown). A tube 16 extends from the hole 14 into a container 17 that can be filled with a liquid 18, typically water.
The container 17 is a generally U-shaped with first and second legs 20, 22 extending upward from a bottom 24. The first leg 20 connects to the modified plug 12 with an air tight seal. The tube 16 extends from the modified plug 12 into the first leg 20 of the U-shaped container 17 to a tube end position 26 below a position 28 to which water, or other equivalent liquid, is filled during use. The second leg 22 is typically open to the atmosphere to allow the water level to adjust without pressure in the second leg 22. It also may be closed to create a difference in water level in the two legs 20, 22 when the first leg 20 is pressurized by air from the heat exchanger's second side in the instance that pressurized air passes through a leak between the heat exchanger's first and second sides, in which case a fill port is provided in the container into which the liquid can be poured into and out of the container 16.
In operation, all pipes and hoses are removed from the heat exchanger to be tested. Other ports 107, 107′ of from each of the first and second sides of the heat exchanger 100 are capped. The leak detector modified plug 12 is secured with an air tight seal in the first heat exchanger port 102 of the heat exchanger's second side. Air pressure is supplied to the second heat exchanger port 104 and the U-shaped container 17 is filled with water to a suitable level above the end 30 of the tube 16. At least the first leg 20 of the container 17 is clear for visible inspection of the water. After a period of time, if there is a leak bubbles 108 will appear in the water as air pressurizes the second side of the heat exchanger 100 through the leak which bubbles are visible through the container 17.
If the bubble test does not quickly disclose a leak, the detector is left for a longer period of time to allow gas to be released from bubbles over that longer time which accumulates and pressurizes the first leg 20 above the water level, which causes a difference in water level between the container's first and second legs 20, 22, which is a more sensitive indicator of a leak.

Claims (3)

1. A method of testing a heat exchanger for leaks without disassembling the heat exchanger comprising the following steps:
a) removing all pipes and hoses from the heat exchanger;
b) capping a first port from each of first and second sides of the heat exchanger;
c) securing a modified plug with an air tight seal to a second port of the heat exchanger's second side, the modified plug having a hole therethrough and further having a tube extending from the modified plug at the hole;
d) placing an end of the tube in a container having water within with the end of the tube below a water level, therein providing fluid communication between the second side of the heat exchanger and the water such that air under pressure in the second side of the heat exchanger is discharged into the water;
e) supplying pressurized air to a second port of the first side of the heat exchanger; and
f) observing bubbles or lack thereof in the water as an indication of said pressurized air leaking from the first side to the second side of the heat exchanger.
2. The method of claim 1 further comprising the step of observing a difference in water level between container first and second legs as an indicator of a leak where the container is U-shaped having first and second legs extending vertically from a container bottom and the tube extends into one leg of the U-shaped container, which is closed with an effective air-tight seal above the water level in that leg.
3. A leak detector adapted to detect a leak in a heat exchanger without disassembly of the heat exchanger, comprising;
a) a container that can be filled with a liquid to a liquid level;
b) a modified port plug adapted to fit in a first heat exchanger port of a heat exchanger's first side, with a hole through the modified port plug;
c) a tube extending from the hole into the container therein providing fluid communication between the first heat exchanger port and said liquid when the liquid is added to the container; and
d) a pressurized gas supply line adapted to connect to a second heat exchanger port of a heat exchanger's second side therein providing pressurized gas to the second heat exchanger port such that when a leak exists in the heat exchanger between the heat exchanger's first and second sides, pressurized gas from the gas supply line passes into the heat exchanger's second side and is discharged through the tube into the container creating visible bubbles in the liquid therein indicating the leak,
e) wherein the container is U-shaped having first and second legs extending vertically from a container bottom and wherein the tube extends into one leg of the U-shaped container, which leg is closed with an effective gas-tight seal above the liquid level such that gas in the bubbles is discharged into the closed container leg above the liquid causing a difference in liquid level between container first and second legs as a further indicator of the leak.
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Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105387976A (en) * 2015-12-14 2016-03-09 江苏天舒电器有限公司 Efficient refrigeration part cleaning water detection tank convenient to use
US10458879B2 (en) * 2014-10-24 2019-10-29 Proactive Analytics Limited Leak testing method and apparatus for use with heat exchangers
US10914652B2 (en) * 2018-05-31 2021-02-09 Wcr, Inc. Leak detection for heat exchanger plate
WO2021103245A1 (en) * 2019-11-28 2021-06-03 璟泰（清远）橡胶工业有限公司 Leakage detection jig
US11268877B2 (en) * 2017-10-31 2022-03-08 Chart Energy & Chemicals, Inc. Plate fin fluid processing device, system and method
US11300365B2 (en) 2018-06-19 2022-04-12 General Electric Company Heat exchanger and leak detection system
US11326975B2 (en) * 2020-03-05 2022-05-10 Mas Automation Corp. Method of sensing leaking gas
CN114878111A (en) * 2022-05-05 2022-08-09 珠海格力电器股份有限公司 Leakage detection method and device for air conditioner heat exchanger
US11434824B2 (en) 2021-02-03 2022-09-06 General Electric Company Fuel heater and energy conversion system
US11592378B1 (en) * 2021-08-30 2023-02-28 Saudi Arabian Oil Company Ache tube leak testing tool
US11591965B2 (en) 2021-03-29 2023-02-28 General Electric Company Thermal management system for transferring heat between fluids
US11674396B2 (en) 2021-07-30 2023-06-13 General Electric Company Cooling air delivery assembly
US11692479B2 (en) 2019-10-03 2023-07-04 General Electric Company Heat exchanger with active buffer layer
US11702958B2 (en) 2021-09-23 2023-07-18 General Electric Company System and method of regulating thermal transport bus pressure
US11788470B2 (en) 2021-03-01 2023-10-17 General Electric Company Gas turbine engine thermal management
US11982497B2 (en) 2022-01-06 2024-05-14 General Electric Company Heat exchanger and leak detection system

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US4103536A (en) * 1977-02-16 1978-08-01 Shell Oil Company Method for detecting leaks in heat exchangers
US4467635A (en) * 1981-08-21 1984-08-28 Stal Laval Apparat Ab Leak detection in heat exchanger tubes and their tube sheet connections
US4783988A (en) 1987-08-25 1988-11-15 Cincinnati Control Dynamics, Inc. Apparatus and method for detecting leaks in welded heat exchanger plates
US4942920A (en) * 1988-06-16 1990-07-24 Polysar Limited Heat exchanger leak detection
US5974863A (en) * 1995-10-16 1999-11-02 Persson; Lars-Anders Method and device for liquid leakage indication
US6009745A (en) * 1997-10-10 2000-01-04 Apv Corporation Method of leak testing an assembled plate type heat exchanger
US6035700A (en) * 1997-10-10 2000-03-14 Apv Corporation Method of leak testing an assembled plate type heat exchanger
US6314794B1 (en) 1998-11-26 2001-11-13 Alcatel Method and apparatus for detecting leaks in heat exchangers for motor vehicles
US6923043B2 (en) * 2001-04-23 2005-08-02 Tetra Laval Holdings & Finance S.A. Method and device for detecting a leak in a heat exchanger, especially a plate-type heat exchanger
GB2411480A (en) * 2004-02-03 2005-08-31 Thornhill Service Method of detecting leaks
US7454956B1 (en) 2005-09-22 2008-11-25 Lopresti William J Heat exchanger leak detection using mass gas flow metering
US7975529B2 (en) * 2005-12-02 2011-07-12 Tetra Laval Holdings & Finance S.A. Method of discovering leakage in a heat exchanger

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4103536A (en) * 1977-02-16 1978-08-01 Shell Oil Company Method for detecting leaks in heat exchangers
US4467635A (en) * 1981-08-21 1984-08-28 Stal Laval Apparat Ab Leak detection in heat exchanger tubes and their tube sheet connections
US4783988A (en) 1987-08-25 1988-11-15 Cincinnati Control Dynamics, Inc. Apparatus and method for detecting leaks in welded heat exchanger plates
US4942920A (en) * 1988-06-16 1990-07-24 Polysar Limited Heat exchanger leak detection
US5974863A (en) * 1995-10-16 1999-11-02 Persson; Lars-Anders Method and device for liquid leakage indication
US6009745A (en) * 1997-10-10 2000-01-04 Apv Corporation Method of leak testing an assembled plate type heat exchanger
US6035700A (en) * 1997-10-10 2000-03-14 Apv Corporation Method of leak testing an assembled plate type heat exchanger
US6314794B1 (en) 1998-11-26 2001-11-13 Alcatel Method and apparatus for detecting leaks in heat exchangers for motor vehicles
US6923043B2 (en) * 2001-04-23 2005-08-02 Tetra Laval Holdings & Finance S.A. Method and device for detecting a leak in a heat exchanger, especially a plate-type heat exchanger
GB2411480A (en) * 2004-02-03 2005-08-31 Thornhill Service Method of detecting leaks
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US7975529B2 (en) * 2005-12-02 2011-07-12 Tetra Laval Holdings & Finance S.A. Method of discovering leakage in a heat exchanger

Cited By (20)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10458879B2 (en) * 2014-10-24 2019-10-29 Proactive Analytics Limited Leak testing method and apparatus for use with heat exchangers
CN105387976B (en) * 2015-12-14 2018-04-13 江苏天舒电器有限公司 A kind of efficient refrigeration accessory water for cleaning inspection groove easy to use
CN105387976A (en) * 2015-12-14 2016-03-09 江苏天舒电器有限公司 Efficient refrigeration part cleaning water detection tank convenient to use
US11268877B2 (en) * 2017-10-31 2022-03-08 Chart Energy & Chemicals, Inc. Plate fin fluid processing device, system and method
US10914652B2 (en) * 2018-05-31 2021-02-09 Wcr, Inc. Leak detection for heat exchanger plate
US11300365B2 (en) 2018-06-19 2022-04-12 General Electric Company Heat exchanger and leak detection system
US11692479B2 (en) 2019-10-03 2023-07-04 General Electric Company Heat exchanger with active buffer layer
WO2021103245A1 (en) * 2019-11-28 2021-06-03 璟泰（清远）橡胶工业有限公司 Leakage detection jig
US11326975B2 (en) * 2020-03-05 2022-05-10 Mas Automation Corp. Method of sensing leaking gas
US11434824B2 (en) 2021-02-03 2022-09-06 General Electric Company Fuel heater and energy conversion system
US11767793B2 (en) 2021-02-03 2023-09-26 General Electric Company Fuel heater and energy conversion system
US11788470B2 (en) 2021-03-01 2023-10-17 General Electric Company Gas turbine engine thermal management
US11591965B2 (en) 2021-03-29 2023-02-28 General Electric Company Thermal management system for transferring heat between fluids
US11674396B2 (en) 2021-07-30 2023-06-13 General Electric Company Cooling air delivery assembly
US11592378B1 (en) * 2021-08-30 2023-02-28 Saudi Arabian Oil Company Ache tube leak testing tool
US20230066570A1 (en) * 2021-08-30 2023-03-02 Saudi Arabian Oil Company Ache tube leak testing tool
US11702958B2 (en) 2021-09-23 2023-07-18 General Electric Company System and method of regulating thermal transport bus pressure
US11982497B2 (en) 2022-01-06 2024-05-14 General Electric Company Heat exchanger and leak detection system
CN114878111B (en) * 2022-05-05 2023-08-18 珠海格力电器股份有限公司 Leakage detecting method and leakage detecting device for air conditioner heat exchanger
CN114878111A (en) * 2022-05-05 2022-08-09 珠海格力电器股份有限公司 Leakage detection method and device for air conditioner heat exchanger

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